Method for drying a substrate

ABSTRACT

A method for drying a workpiece using an apparatus comprising a liquid bath for immersing said workpiece, a deionized water supply for supplying deionized water to said bath, a partially enclosed volume of heated inert gas located above said liquid bath and a heated inert gas supply for supplying heated inert gas. A first holder is used for holding said workpiece in said liquid bath with a vertical orientation between the first holder and said liquid bath and a second holder, comprising a horizontal member, that is able to hold said at least one workpiece in such a way as to substantially prevent said workpiece from sliding along said horizontal member.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. application Ser. No.13/463,880 filed on May 4, 2012, issued as U.S. Pat. No. 8,544,482 onOct. 1, 2013 which is a Divisional of U.S. application Ser. No.12/514,235 filed 8 May, 2009 issued as U.S. Pat. No. 8,257,507 on Sep.4, 2012, which is a National Stage application filed under §371 of PCTApplication No. PCT/MY2007/000073 filed Nov. 7, 2007 which claimspriority from Malaysian Patent Application No. PI 20064470 filed Nov. 9,2006, the entire disclosures of which are incorporated herein theirentirety.

FIELD OF THE INVENTION

This invention relates to a method and apparatus for drying a workpiecesuch as a substrate used in magnetic disk or integrated circuitmanufacturing.

BACKGROUND OF THE INVENTION

In many manufacturing processes it is necessary to treat a workpiecewith a liquid and then dry the workpiece. For example, during themanufacturing of magnetic disks, one typically performs the followingmanufacturing steps:

1. First a nickel-phosphorus layer is plated onto an aluminum substrate;

2. The nickel-phosphorus layer is polished and textured;

The substrate is cleaned, rinsed and dried;

A series of layers are sputtered onto the substrate, e.g., an underlayersuch as sputtered NiP or Cr, a magnetic cobalt alloy, and a protectivehydrogenated carbon overcoat.

Immediately prior to sputtering, the substrate is cleaned and thendried. It is extremely important that when the substrate is dried, thereare no impurities left on its surface.

A well known drying technique relies upon hot de-ionized (DI) water torinse and promote drying of the disk. By way of the hot DI water, theliquid on the wafer evaporates faster and more efficient than standardroom temperature DI water. However, hot water often introduces stains onthe disk, and also promotes build-up of bacterial and other particles.Another limitation is water is often expensive to heat, and hot DI wateris also an aggressive solvent. As an aggressive solvent, it oftendeteriorates equipment and facilities, thereby increasing maintenanceoperation costs. One object of our invention is to overcome thisproblem.

Also, during the process of lifting the workpiece from the DI water, aholder arm is always in contact with the disk. This leaves thepossibility that there will be a contamination or drying mark at thepoint where the disk is held during drying. Fung et al (U.S. Pat. No.6,216,709 E1) addresses this problem by using a two stage liftingprocess, whereby a drying portion of the disk is not held by a wetholding mechanism. In spite of this, there could be embellishments wherethe holding mechanism attaches to the disk. Another object of ourinvention is to overcome this problem.

SUMMARY OF THE INVENTION

This invention aims to provide a more effective and efficient way ofdrying workpieces such as magnetic disks. This is achieved by the use ofunheated DI water as the rinsing agent and a heated inert gas as thedrying agent. The unheated DI water addresses a number of the problemslisted above, namely saving the energy consumed to heat the water, andlessening the aggressiveness of the DI water when compared with heatedDI water. The heated inert gas, such as nitrogen provides for efficientdrying of the disk. The heating of nitrogen requires a much smalleramount of heat than water.

The use of a second dry holder to lift the disk, and its position at thecentral opening of the disk eliminates any embellishments or marks onthe disk.

This invention comprises a container for holding a liquid and enclosinga volume for a heated inert gas, and a first and second holder for eachof one or more workpieces such as disks. The disk is a circumferentialflat disc with a centrally located circumferential opening. The disk isplaced onto the first holder after which the first holder lowers downuntil the disk is entirely immersed in the liquid. Thereafter, the firstholder lifts the disk up to a point whereby a central opening in thedisk is partially or fully above the liquid surface. In this position,the first holder will be taken over by a second holder and the take overby the second holder takes place where the first holder remainssubmerged in the liquid bath. The second holder will slide horizontally,penetrating through the openings of workpieces. The first holder is thenremoved, so that the workpieces are no longer held by the first holderand is held by the second holder. The second holder then moves upwards,thereby contacting an upper part of said inner diameter and transferringmotion. Whilst the take over by the second holder takes places, theworkpieces remain continuously lifted by the first holder and when theworkpieces are finally held by the second holder, the lifting speed ofthe second holder does not differ from the lifting speed of the firstholder. In other words, the raising of the workpieces happen at asubstantially constant speed.

Next, the second holder attaches to an inner diameter of the disk formedby the central opening, and proceeds to lift the disk away from thefirst holder and entirely out of the liquid and into the volume ofheated inert gas. In this way, there is no contact of the drying diskwith a wet holder. The location of the second holder at the centralopening of the disk also eliminates any marks or embellishments on thedisk.

Another specific embodiment of this invention is a method for drying aworkpiece that has a substantially flat disc shape defining an outerdiameter and a substantially circumferential opening at a centerlocation defining an inner diameter, comprising the acts of immersingthe workpiece in an unheated liquid bath, and raising the workpiece outof said liquid bath into a substantially enclosed volume of heated inertgas. The heated inert gas may be selected from a group consisting ofnitrogen, helium, argon, and mixtures thereof. The act of immersing theworkpiece in the unheated liquid bath may comprise the steps of placingsaid workpiece on a first holder, said first holder able to move in sucha fashion as to cause a substantially vertical movement of saidworkpiece between a highest position and a lowest position, wherein atsaid highest position the said workpiece is located entirely abovesurface of said liquid bath and at said lowest position the saidworkpiece is immersed entirely in the said liquid bath, and said firstholder then lowering said workpiece to said lowest position. The act ofraising the workpiece out of said liquid bath and into a substantiallyenclosed volume of heated inert gas may comprise the steps of said firstholder raising the said workpiece to an intermediate position betweensaid lowest and said highest positions, wherein at said intermediateposition the said circumferential opening is partially or completelyabove the surface of said liquid bath, a second holder attaching to saidinner diameter of said workpiece, said second holder raising theworkpiece so that the said workpiece is entirely above the surface ofsaid liquid bath.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an overall perspective view of an embodiment of thisinvention.

FIG. 2 shows a cut away perspective view of an embodiment of thisinvention.

FIGS. 3 a to 3 f shows views of the sequence of an embodiment of thisinvention

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to FIGS. 1 and 2, the substrate drying apparatus (10)according to one embodiment of our invention comprises a first holder(20) for holding one or more workpieces such as substrates (14). In oneembodiment, substrates (14) can be substrates used during themanufacture of magnetic disks. Such substrates typically have an outerdiameter (16) of 65, 84, 95 or 130 mm. Such substrates also typicallyhave a centrally located circumferential opening formed by an innerdiameter (18). However, this apparatus may also be used in conjunctionwith substrates having other shapes and diameters, or in othermanufacturing processes, e.g., semiconductor manufacturing.

In one embodiment, first holder (20) is a tray-like structure comprisinga plurality of slots (22) for supporting substrates (14) in such a waythat the substrates (14) will not tend to spontaneously move downwardsor sideways in relation to the said plurality of slots (22). In orderfor the first holder (20) to lower and raise the substrates (14), itrides on a threaded screw (not shown) which is rotated by a motor (notshown) to raise and lower first holder (20). When being raised andlowered, first holder (20) rides along a ball or vertical slider (88).

FIGS. 1 and 2 also show a second holder in the form of a rod (30). Therod (30) has a plurality of notches (32) regularly spaced and facingupwards. Each of these notches (32) can hold a single substrate (14) andprevent the substrate (14) from sliding along the rod (30). This secondholder is slidably fixed to a horizontal slide (34) such that whensliding along this horizontal slide (34), the rod (30) moves along itslongitudinal axis. The horizontal slide (34) is in turn slidably fixedto a vertical slider (88). However, in another embodiment this setupcould be exchanged, with the second holder slidably fixed to a secondvertical slide and the second vertical slide in turn slidably fixed to asecond horizontal slide. The sliding movement is produced by threadedscrew (not shown) which is rotated by a motor (not shown). In thisembodiment, the substrates (14) are first lowered into an unheatedliquid bath (60), preferably of unheated DI water within a container(40). Preferably, the liquid bath is substantially free from particlesgreater than about 0.2 microns in diameter. After the substrates (14)are fully immersed, a cover (42) lowers to partially enclose a volumeabove the liquid bath (60). An inert gas, such as nitrogen is pumpedinto the volume via a gas inlet (50). Prior to this, the inert gas isheated in a gas heater (55). The inert gas is preferably heated to atemperature below a temperature at which the liquid in the liquid bath(60) is volatile. The substrates (14) are then raised by the firstholder (20) to an intermediate position at which point thecircumferential opening formed by the inner diameter (18) is partiallyor completely above the surface of said liquid bath (60). The secondholder rod (30) then slides horizontally and penetrates thecircumferential openings of the substrates (14). The second holder rod(30) then moves upwards, thereby contacting an upper part of said innerdiameter (18) and transferring motion to said substrate (14), thuslifting it.

The second holder rod (30) then moves upwards, thereby contacting anupper part of said inner diameter (18) and transferring motion to saidsubstrate (14), thus lifting it.

Container (40) is typically filled to overflowing with liquid (60). Anoverflow channel (44) surrounds the top of container (40) to receiveoverflowing excess liquid (60). Vents (46) are located on the sides ofthe partially enclosed volume and above the liquid bath (60) to allowexcess nitrogen to exit.

FIGS. 3 a to 3 f show part of the sequence associated with an embodimentof this invention. A substrate (14) is placed into the slots (22)located on the first holder tray (20). The first holder tray (20) isthen lowered by sliding down the vertical slider (88) until thesubstrate (14) is fully immersed in the liquid bath (60). The cover (42)is then lowered down over a partially enclosed volume defined by thesurface of the liquid bath (60) below, vents (46) at the sides, and thecover (42) and ceiling (48) above. An inert gas such as nitrogen,pre-heated by a heater (55), is then pumped into the partially enclosedvolume via a gas inlet (50).

The substrates (14) are then raised by the first holder (20) to anintermediate position at a point which the circumferential openingformed by the inner diameter (18) is partially or completely above thesurface of said liquid bath (60). In this position, the first holder(20) will be taken over by a second holder rod (30) and the take over bythe second holder (30) takes place where the first holder (20) remainssubmerged in the liquid bath (60). The second holder rod (30) will slidehorizontally, penetrating through the openings of substrates (14). Thefirst holder (20) is then removed, so that the substrates (14) are nolonger held by the first holder (20) and is held by the second holder(30). The second holder rod (30) then moves upwards, thereby contactingan upper part of said inner diameter and transferring motion. Whilst thetake over by the second holder (30) takes places, the substrates (14)remain continuously lifted by the first holder (20) and when thesubstrates (14) are finally held by the second holder (30), the liftingspeed of the second holder (30) does not differ from the lifting speedof the first holder (20). While the invention has been described withrespect to specific embodiments, those skilled in the art will recognizethat changes can be made in form and detail without departing from thespirit and scope of the invention. For example, the various holdingmechanisms and containers may be constructed from any appropriatematerial. In lieu of deionized water, our invention can be used inconjunction with other liquids. Such liquids can be used for washing,rinsing or performing other manufacturing processes in conjunction withthe substrates. In lieu of nitrogen, other inert gases such as, argon orother inert gases or combinations thereof can be used. Accordingly, allsuch changes come within our invention.

The invention claimed is:
 1. A method for washing and drying at leastone workpiece, said workpiece having a substantially circumferentialopening at a center location defining an inner diameter of saidworkpiece, the method comprising: immersing said workpiece within liquidforming a liquid bath, wherein the liquid comprises deionized water;supplying heated inert gas to a partially enclosed volume above saidliquid bath; holding said workpiece within said liquid bath with avertical orientation using a first holder, and thereafter, drying saidworkpiece, said drying comprising separating said at least one workpiecefrom said liquid bath, said separating step comprising: providing asecond holder, said second holder comprising a horizontal member, saidhorizontal member being structured to hold at least one workpiece insuch a way as to substantially prevent said workpiece from sliding alongsaid horizontal member, and moving said second holder laterally so thatsaid at least one workpiece can be held on said horizontal member,wherein said moving laterally causes said horizontal member to penetratethe circumferential opening of said workpiece and causes said horizontalmember to attach to said circumferential opening of said workpiece. 2.The method according to claim 1, wherein said first holder comprises atray with a plurality of slots such that each slot is able to hold saidat least one workpiece in such a way that the at least one workpiecewill not tend to spontaneously move downwards or sideways in relation tosaid plurality of slots.
 3. The method according to claim 1, wherein inthe separating step: when moved in an upwards direction, the horizontalmember contacts an upper part of said inner diameter of thecircumferential opening of said at least one workpiece and causes saidhorizontal member to attach to said circumferential opening of saidworkpiece.
 4. The method according to claim 1, further comprising usinga vertical slider to control movement of the first holder.
 5. The methodaccording to claim 1, further comprising using a horizontal slider and avertical slider to effect movement of said second holder.
 6. The methodaccording to claim 1, further comprising, raising said at least oneworkpiece at a substantially constant speed, provided by a transition ofthe workpiece between the first holder to the second holder.
 7. Themethod according to claim 1, further comprising providing a heat sourcefor heating said inert gas.
 8. The method according to claim 1, furthercomprising providing said horizontal member with regularly spacednotches, each of said notches for holding said at least one workpiece.9. The method according to claim 1, said drying further comprisingoperating said second holder so as to cause said workpiece to changefrom being in contact with said liquid to being in contact with said gasin a substantially vertical movement.
 10. The method according to claim1, further comprising operating said second holder so that it is able tosecure said at least one workpiece as the workpiece is changed frombeing in contact with said liquid to being in contact with said gas in asubstantially vertical movement.
 11. The method according to claim 1,further comprising operating an apparatus in a manner to cause transferof said workpiece from being in contact with said liquid to being incontact with said gas.
 12. The method according to claim 3, furthercomprising using a vertical slider to control movement of the firstholder.
 13. The method according to claim 3, further comprising using ahorizontal slider and a vertical slider to effect movement of saidsecond holder.
 14. The method according to claim 3, further comprisingraising said at least one workpiece at a substantially constant speed,provided by a transition of the workpiece between the first holder tothe second holder.
 15. The method according to claim 3, furthercomprising providing a heat source for heating said inert gas.
 16. Themethod according to claim 3, further comprising providing saidhorizontal member with regularly spaced notches, each of said notchesfor holding said at least one workpiece.
 17. The method according toclaim 3, said drying further comprising operating said second holder soas to cause said workpiece to change from being in contact with saidliquid to being in contact with said gas in a substantially verticalmovement.
 18. The method according to claim 3, further comprisingoperating said second holder so that it is able to secure said at leastone workpiece as the workpiece is changed from being in contact withsaid liquid to being in contact with said gas in a substantiallyvertical movement.
 19. The method according to claim 3, furthercomprising operating an apparatus in a manner to cause transfer of saidworkpiece from being in contact with said liquid to being in contactwith said gas.
 20. The method according to claim 3, wherein said firstholder comprises a tray with a plurality of slots such that each slot isable to hold said at least one workpiece in such a way that the at leastone workpiece will not tend to spontaneously move downwards or sidewaysin relation to said plurality of slots.